Tailgate electrical/mechanical repair

[Driftwood]

My tailgate needed serious maintenance.
I gutted it of all electrical wiring, mechanical parts, glass, inner & outer wipes, Tailgate Glass Side Channels, and outer tailgate key switch.

I ordered and installed new;
Tailgate Window Lift Pins with Upgraded Clip Design
Tailgate Glass Side Channels
Tailgate Window Lifter Seal
Tailgate Wipe Inner

Through time I squirreled parts which included;
Lift mechanism w/electric motor
Tailgate Wipe Outer
Tailgate wiring harness
Inner tailgate key switch
Cutoff switch

I also bought a Window Wipe (Window Belt) Molding Removal Tool.

I considered doing the tailgate wiring upgrade. But I strive to keep things stock to keep costs down.

Here are some pics of the work I've completed so far.

The following pic shows my stock lift mechanism.

The one below it I salvaged. It had a nice motor as well as both springs and spring cups on the pins.



The lift pins were toast. And the PO had removed the factory spring and spring cup from this pin.

Also, this pin was missing its retainer clip. Instead, the PO had tack welded a flat washer onto the end of the pin. I had to grind it off so I could remove the window lift channel from it.



The next five pics detail the removal of the guide pin. It is pressed in place. DO NOT GRIND OFF TO MUCH ARM MATERIAL. Or else you will have to install a lock washer with the new lift pins.









Keep the Spring and spring cup. Do not discard.

[Driftwood]

The following pics are of the installation of the new lift pins, springs and spring cups.

[Driftwood]

I installed new Inner Tailgate Wipes. My old ones were devoid of all felt. They are kept in place with two screw and washers. Save your old ones. Do not discard them. If you do, off you go to the junk yard to source replacements.

[SJTD]

Take a look at Post #43: http://ifsja.org/forums/vb/showthrea...=164564&page=3

You should open up that lift motor. Might look like mine.

[lkmarsh]

Wow. Just Wow.

Some of the best photography I've seen in a tech write-up. Who's your parts source?

Converted two of my three tailgates to relays to protect the stock switches.
The Impala gets the treatment next week, using a factory reversing relay.
The Jeep tailgate switch is easier to find than the Chevy item, and much cheaper. For now.

[GWNashville]

Awesome job. I need to get after that.

[Driftwood]

Take a look at Post #43: http://ifsja.org/forums/vb/showthrea...=164564&page=3

You should open up that lift motor. Might look like mine.

Thank you for the advice!

I found Achilles very informative 2015 write-up at http://www.ifsja.org/forums/vb/showp...6&postcount=63

And elskeptico's 2005 write-up at http://www.ifsja.org/forums/vb/showp...88&postcount=1

[Driftwood]

Lock the spring loaded arm prior to removing the electric motor


Remove electric motor. It is secured with three 7/16 bolts.


After removing the motor, remove the small Philips screw.

[asudchiman]

Wow. Nice work.
You have been busy.

[Driftwood]

Remove the cover and set aside.


Grab the splined shaft and remove the gear assembly.






Tap on the splined shaft to separate it from the plastic gear.

[Driftwood]

OH THE JOY!!

[Driftwood]

Both electric motors of mine were in this condition.

[SJTD]

Last pichers I can see are from 7/1. The rest are big "-".

[scout4bta]

no pics

Same here, no pics from post #8 thru #11.

[Driftwood]

Went to Lowes for spacers and grease.





The spacers are a perfect fit.